US4626410A - Method of making composite material of matrix metal and fine metallic particles dispersed therein - Google Patents

Method of making composite material of matrix metal and fine metallic particles dispersed therein Download PDF

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Publication number
US4626410A
US4626410A US06/620,176 US62017684A US4626410A US 4626410 A US4626410 A US 4626410A US 62017684 A US62017684 A US 62017684A US 4626410 A US4626410 A US 4626410A
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United States
Prior art keywords
metal
particles
nozzle
composite material
metallic
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Expired - Lifetime
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US06/620,176
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English (en)
Inventor
Hirohisa Miura
Hiroshi Satou
Toshio Natsume
Hidenori Katagiri
Yoshiro Hayashi
Masahiro Taguchi
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Toyota Motor Corp
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Toyota Motor Corp
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Assigned to TOYOTA JIDOSHA KABUSHIKI KAISHA, 1, TOYOTACHO, TOYOTA-SHI, AICHI-KEN, JAPAN reassignment TOYOTA JIDOSHA KABUSHIKI KAISHA, 1, TOYOTACHO, TOYOTA-SHI, AICHI-KEN, JAPAN ASSIGNMENT OF ASSIGNORS INTEREST. Assignors: HAYASHI, YOSHIRO, KATAGIRI, HIDENORI, MIURA, HIROHISA, NATSUME, TOSHIO, SATOU, HIROSHI, TAGUCHI, MASAHIRO
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F9/00—Making metallic powder or suspensions thereof
    • B22F9/02—Making metallic powder or suspensions thereof using physical processes
    • B22F9/12—Making metallic powder or suspensions thereof using physical processes starting from gaseous material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D27/00—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/02—Making non-ferrous alloys by melting
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C9/00—Alloys based on copper

Definitions

  • the present invention relates to a two phase or composite material using a first metallic material as a matrix material and with fine particles made of a second metal dispersed therein as reinforcing material, and to a method of making such a composite material.
  • metal-metal particle dispersion composite materials have been made by utilizing reinforcing particles with diameters in the range of from one micron to tens of microns, which have been formed by mechanical breaking methods or atomization methods.
  • the method typically used for dispersing these metal reinforcing particles in the molten matrix metal has been either simply to mix them mechanically, or alternatively to utilize the so called jet dispersal method in which a jet of inert gas such as argon gas carrying the metallic reinforcing particles mixed with is introduced into the molten matrix metal.
  • metallic particles with an average diameter of less than one micron cannot be economically produced by such mechanical breaking methods or atomization methods, and, since the metallic particles made as described above have small surface activity and have relatively poor wettability with respect to the molten metallic matrix material, the problem arises that unevenness in the distribution in the vertical direction of the metallic particles inevitably tends to occur between higher and lower strata of the molten composite material, due to the difference in specific gravities between the metallic particles and the matrix metal. In other words, it is very difficult or impossible to evenly distribute such fine metallic reinforcing particles in the molten matrix metal by mechanical mixing or by the jet dispersal method.
  • these and other objects relating to a method are accomplished by a method of making a composite material comprising a first metallic material as matrix material and fine particles of a second metal dispersed therein, wherein vapor of said second metal is rapidly cooled by being adiabatically expanded through a nozzle, and a jet flow from said nozzle is directed into a mass of said first metallic material in molten state.
  • the flow impinging on the surface of the molten first metal matrix material contains extremely fine particles of the second metal with diameters in the range of a few hundreds of angstroms, which have just solidified and accordingly have extremely high surface activity. These very active and very fine particles are entrained into the molten first metal matrix material by impinging on the surface thereof at high speed, and become thoroughly and evenly mixed therein. Good mixing of the particles of the second metal with the molten first metal matrix material is effected by the fact that the high speed jet impinging on the surface of the molten mixture has a strong effect to churn it up and to render it uniformly mixed.
  • This method of making a composite material may be readily adapted to continuous rather than batchwise operation, by causing the molten first metal matrix material to flow at a fixed flow rate relative to the nozzle.
  • FIG. 1 is a schematic structural sectional view showing a metal reinforcing particle-metal matrix type reinforced material production device which is used for performing certain preferred embodiments of the method of the present invention so as to make certain of the preferred embodiments of the material of the present invention;
  • FIG. 3 is a partial longitudinal sectional view showing a convergent type nozzle, which can be used as an alternative type of cooling nozzle in the device shown in FIG. 1 for performing certain of the preferred embodiments of the method of the present invention
  • FIG. 4 which relates to the prior art, shows the process of making a comparison sample of metal reinforcing particle-metal matrix type reinforced material according to a mechanical mixing method
  • FIG. 5 is a transmission electron microscope photograph of a metal reinforcing particle-metal matrix type reinforced material using molybdenum particles as the reinforcing material and copper alloy as the matrix material, which is a particular preferred embodiment of the material according to the present invention.
  • the reference numeral 1 denotes a furnace shell, which is formed as a substantially enclosed container; and a melting pot 2 is disposed within this furnace shell 1.
  • This melting pot 2 comprises a gas preheating chamber 5, to which gas can be fed from the outside as will be described later via a gas introduction port 4 which is controlled by a valve 3, and further comprises a metal vapor production chamber 6 communicated with said gas preheating chamber 5.
  • a heater 7 for keeping the interiors of the gas preheating chamber 5 and of the metal vapor production chamber 6 heated up to an appropriately high temperature T 1 ; and thus metal charged into the metal vapor production chamber 6 is melted into a molten metal mass 8 and is further vaporized into metallic vapor, to fill the chamber 6 and to mix with the gas (if any) introduced through the port 4.
  • a container 14 for containing a mass 13 of molten metal matrix material (which is typically of course a different kind of metal from the kind of the metal mass 8); and this container 14 and its contents are arranged to be kept at an appropriate high temperature by a heater 16.
  • a heater 16 which is driven by a motor 17; in fact, this is not done in the case of all the preferred embodiments, and so these elements are shown by double dotted lines to indicate that they are optional.
  • a vacuum pump 21 is connected to the composite material production zone 10 via a valve 20 and a conduit 19, so as to keep the zone 10 and the metal vapor production chamber 6 evacuated to desired pressures, which will hereinafter be designated as P 2 and P 1 respectively.
  • the mixture gas in the metal vapor production chamber 6 passed into the conduit 11 and downwards therein, to be squirted out of the convergent-divergent nozzle 12 into the composite material production zone 10.
  • the valve 3, the vacuum pump 21 and the valve 20 were so regulated as to keep the pressure P 1 in the metal vapor production chamber 6 at approximately 2 torr, and the pressure P 2 in the zone 10 at approximately 0.1 to 0.2 torr.
  • the mixture gas of molybdenum vapor and argon which had passed through the convergent-divergent nozzle 12 and had been cooled by rapid adiabatic expansion cooling therein was cooled to a temperature T 2 of approximately 830° C.
  • this composite material mass was generally formed as an ingot 22 (see FIG. 2) which had a diameter of approximately 80 mm and a height of approximately 80 mm. Then, as indicated in FIG. 2, a cylindrical body 24 was cut out from this ingot 22 along its center line 23, and three cylindrical samples A, B, and C, each approximately 10 mm in diameter and 10 mm high, were cut from this cylindrical body 24 at approximate depths from its upper surface 25 of 15 mm, 40 mm, and 65 mm respectively.
  • the molybdenum particles were produced to be of extremely small size to be from 80 to 230 angstroms, and that these particles were mixed in with the copper alloy in substantially uniform fashion through the entire extent of the copper alloy, with regard to its vertical dimension, as evidenced by the comparison of the weight percentage of molybdenum particles between the three sample pieces A, B, and C.
  • Another type of composite material was manufactured as a modification of the first embodiment, using the apparatus described above, from the same combination of two materials, in the same way as the first preferred embodiment described above, except that a motor 17 and a propeller 18 as shown in FIG. 1 by the double dotted lines were used for stirring the molten copper alloy up during the infusion of the molybdenum particles thereinto from the jet flow 15.
  • Still another type of composite material was manufactured as another modification of the first embodiment, using the apparatus described above, from the same combination of two materials, in the same way as the first preferred embodiment described above, except that a convergent nozzle 26 as shown in section in FIG. 3 was used for passing the jet flow 15 through to squirt it into the composite material production zone 10, instead of the convergent-divergent nozzle 12 of the first preferred embodiment.
  • a convergent nozzle 26 as shown in section in FIG. 3 was used for passing the jet flow 15 through to squirt it into the composite material production zone 10, instead of the convergent-divergent nozzle 12 of the first preferred embodiment.
  • three cubic samples were cut from the composite material column located as before, and for each of these samples A, B, and C the weight percentage of molybdenum particles, the range of particle diameters, and the average particle diameter, were measured. The results are shown in Table 2, in its column III. The average particle diameter was now approximately 310 angstroms.
  • Still another type of composite material was manufactured as another modification of the first embodiment, using the apparatus described above, from the same combination of two materials, in the same way as the first preferred embodiment described above, except that no argon gas was mixed into the molybdenum vapor in the metal vapor production chamber 6, but instead the jet flow 15 was pure molybdenum vapor.
  • three cubic samples were cut from the composite material column located as before, and for each of these samples A, B, and C the weight percentage of molybdenum particles, the range of particle diameters, and the average particle diameters were measured. The results are shown in Table 2, in its column IV. Comparison of the data in columns I and IV will show us the remedial value of the effect of the argon gas used as a carrier for the molybdenum vapor.
  • this fourth embodiment of the present inventin was still considered to be effective for promoting mixing of molybdenum particles in a substantially uniform fashion through the entire extent of the copper alloy, when compared with the conventional methods.
  • a comparison sample of composite material was made by dispersing in molten copper alloy, according to a mechanical mixing method, molybdenum particles (made by Nippon Kinzoku K.K.) of purity 99.8% which were prepared by pulverization.
  • the molybdenum particles were placed into a particle supplier 28 of an injection device 30 and were picked up by a stream of argon gas (from a source not shown in the drawing) which was passed through a conduit 27, so as to be entrained into the argon gas stream and to be injected from the injection device 30 into a stream 32 of molten copper alloy which was being poured fom a container 31 into a melting pot 33.
  • a piece of composite material 80 mm in diameter and 80 mm in height was produced in this way, and analogous samples A, B, and C were cut therefrom to the samples of the four variations of the first embodiment of the present invention described above.
  • the weight percentage of molybdenum particles, the range of particle diameters, and the average particle diameters were measured; the results are shown in Table 2, in its column entitled “Comparison Sample ". It can be seen that the distribution of the molybdenum particles was much more uneven than in the case of the various described embodiments of the present invention, and also the particles were very much larger in size, as well as being quite heterogenous in their diameters.
  • the production conditions in this second preferred embodiment were as follows: the material charged in the melting pot 2 was approximately 100 gm of cobalt; the introduced gas through the gas introduction port 4 was argon gas; the temperature T 1 was approximately 1900° C.; pressure P 1 was approximately 3 torr; temperature T 2 was approximately 800° C. or less; pressure P 2 was approximately 0.5 to 0.6 torr; and temperature T 3 was approximately 1000° C. to 1050° C.
  • Table 3 the data in its columns II, III, and IV shows the results of modifications with regard to the second embodiment of the same kinds as those modifications made with regard to the first embodiment; and the column entitled “Comparison Sample” shows the weight percentage of cobalt particles, the range of particle diameters, and the average particle diameters relating to a comparison sample, made in the same way as the comparison sample with regard to the first embodiment but using cobalt particles made by Outokump Co. as the reinforcing material. From these data, it will be appreciated that the same kinds of modifications to the method of the second embodiment produced the same kinds of differences with regard to the distribution of particles in the matrix metal body, the range of particle diameters, and the average particle diameters in the composite materials obtained, as in the first embodiment.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Manufacture Of Alloys Or Alloy Compounds (AREA)
  • Manufacture Of Metal Powder And Suspensions Thereof (AREA)
US06/620,176 1983-07-13 1984-06-13 Method of making composite material of matrix metal and fine metallic particles dispersed therein Expired - Lifetime US4626410A (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
JP58127439A JPS6021345A (ja) 1983-07-13 1983-07-13 金属粒子分散金属マトリツクス複合材料の製造方法
JP58-127439 1983-07-13

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EP (1) EP0131797B1 (ja)
JP (1) JPS6021345A (ja)
DE (1) DE3469443D1 (ja)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5022932A (en) * 1987-03-25 1991-06-11 Matsushita Electric Works, Ltd. Rapid solidification of metal-metal composites having Ag, Au or Cu atrix
US5348703A (en) * 1990-10-16 1994-09-20 The Secretary Of The State For Defence In Her Britannic Majesty's Government Of The United Kingdom Of Great Britain And Northern Ireland Vapor deposition apparatus and method
US5980604A (en) * 1996-06-13 1999-11-09 The Regents Of The University Of California Spray formed multifunctional materials

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6251159B1 (en) * 1998-12-22 2001-06-26 General Electric Company Dispersion strengthening by nanophase addition

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CA802133A (en) * 1968-12-24 Contemporary Research Production of dispersion hardened materials
US4484943A (en) * 1982-03-01 1984-11-27 Toyota Jidosha Kabushiki Kaisha Method and apparatus for making a fine powder compound of a metal and another element
US4508682A (en) * 1982-04-02 1985-04-02 Toyota Jidosha Kabushiki Kaisha Method for making composite material including matrix metal and metal cored ceramic surfaced fine powder material

Family Cites Families (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR1206427A (fr) * 1957-11-09 1960-02-09 Deutsche Edelstahlwerke Ag Alliage pour circuits magnétiques à compensation thermique
DE1458174C3 (de) * 1963-10-01 1975-08-21 Oxymet Ag, Meilen (Schweiz) Verfahren zur Herstellung von Metallpulver oder -granulat durch Verdüsen
US3286334A (en) * 1965-07-16 1966-11-22 Contemporary Res Inc Production of dispersion hardened materials
US4008081A (en) * 1975-06-24 1977-02-15 Westinghouse Electric Corporation Method of making vacuum interrupter contact materials
JPS5424204A (en) * 1977-07-25 1979-02-23 Hitachi Zosen Corp Preparation of alloy of particle dispersion type
US4304600A (en) * 1979-11-01 1981-12-08 Bell Telephone Laboratories, Incorporated Manufacture of high-strength metallic articles

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CA802133A (en) * 1968-12-24 Contemporary Research Production of dispersion hardened materials
US4484943A (en) * 1982-03-01 1984-11-27 Toyota Jidosha Kabushiki Kaisha Method and apparatus for making a fine powder compound of a metal and another element
US4508682A (en) * 1982-04-02 1985-04-02 Toyota Jidosha Kabushiki Kaisha Method for making composite material including matrix metal and metal cored ceramic surfaced fine powder material

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5022932A (en) * 1987-03-25 1991-06-11 Matsushita Electric Works, Ltd. Rapid solidification of metal-metal composites having Ag, Au or Cu atrix
US5348703A (en) * 1990-10-16 1994-09-20 The Secretary Of The State For Defence In Her Britannic Majesty's Government Of The United Kingdom Of Great Britain And Northern Ireland Vapor deposition apparatus and method
US5980604A (en) * 1996-06-13 1999-11-09 The Regents Of The University Of California Spray formed multifunctional materials

Also Published As

Publication number Publication date
JPH0472894B2 (ja) 1992-11-19
DE3469443D1 (en) 1988-03-31
EP0131797B1 (en) 1988-02-24
EP0131797A1 (en) 1985-01-23
JPS6021345A (ja) 1985-02-02

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